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Old 26-08-2016, 09:25   #1
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Relay - heat in wire. Replacement part?

My French built Beneteau has a 4 pin relay, photo below, with the right side red wire quite hot. I can hold my finger on it for 4 seconds before its too hot.

The engine is off. Solar panels are on generating about 10 amps.

Is this an indicator of trouble?

I have searched the net unsuccessfully for a replacement relay to no avail. There's a confusing myriad of them.

Can you identify a replacement?

Details: G Cartier
12 V 50A
4 pin

I really have no idea what its for.
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Old 26-08-2016, 09:32   #2
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Re: Relay - heat in wire. Replacement part?

Some relays are hot all the time.. A normally open relay stays energized while in use. If that spade connector is loose it could heat up the wire.
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Old 26-08-2016, 10:03   #3
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Re: Relay - heat in wire. Replacement part?

Its a very common relay..12v /50A normally open. They are available from Bosch, Tyco, etc. and they are easy to get from NAPA or other automotive stores.

If the red lead is warm, the relay is energized and current is flowing thru it, so the trick is to find out what controls it.

Some time ago Beneteau used such a relay to control their windless circuits. The relay was wired to the ignition so that the windless could not be used unless the engine was running and the alternator putting out current.

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Old 26-08-2016, 10:33   #4
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Re: Relay - heat in wire. Replacement part?

Here's a viable replacement.

https://www.amazon.com/dp/B0068M2LYC...HV8GQDCSY0QAPK
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Old 26-08-2016, 18:13   #5
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Re: Relay - heat in wire. Replacement part?

it's more likly the connections then the relay. cut off the wire ends and replace them. and clean the relay terminals. and try again. if still hot then replace the relay. but now you have new connections as well so no harm in doing that first.
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Old 27-08-2016, 03:17   #6
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Re: Relay - heat in wire. Replacement part?

I think you need to find out what it is doing. It looks to be connected to a solenoid, maybe driving the water pump. If so, or if it is a similar temporary function it should not be on often, so should not have the chance to warm up slowly, assuming? that is what is happening. If so, something else is wrong.

If the relay coil is on constantly then it will get warm, but should not get as hot as you describe, I suspect it is a dirty or corroded connection causing a high current draw and heating of the contacts only. This can be dangerous if the wire isn't protected well.

If it needs to be on all the time then a relay is wasteful of power. Get a circuit breaker instead or a fused switch.
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Old 27-08-2016, 08:51   #7
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Re: Relay - heat in wire. Replacement part?

Mark, Could this 50A relay control a short run-time heavy-duty pump, like a macerator or deck wash?
High heat = resistance somewhere.
Good luck
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Old 27-08-2016, 09:06   #8
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Re: Relay - heat in wire. Replacement part?

Mark, If the connector and wire on the right side is getting hot and the red on the left isn't you most likely have a bad connection on the right. Pull the connector on the left and if the right doesn't cool off the relay is shorted. Other wise remake the connector on the right.
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Old 27-08-2016, 09:42   #9
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Re: Relay - heat in wire. Replacement part?

Thanks for everyones advice.

The solenoid splits the battery banks for charging so the engine battery gets bulk power on the engine start, supplied by the alternator. It then supplies bulk to the house bank.
Or this is what i am lead to believe. I change the solenoid about every year.

I hope the relay is easily available because none on the internet show the same connection/switching as shown on mine.

Needless to say theres no length in the red wires to cut and repace the connectors. Boats!

I shall report back.
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Old 27-08-2016, 10:16   #10
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Re: Relay - heat in wire. Replacement part?

Quote:
Originally Posted by MarkJ View Post
Thanks for everyones advice.
Quote:
Originally Posted by MarkJ View Post

The solenoid splits the battery banks for charging so the engine battery gets bulk power on the engine start, supplied by the alternator. It then supplies bulk to the house bank.
Or this is what i am lead to believe. I change the solenoid about every year.

I hope the relay is easily available because none on the internet show the same connection/switching as shown on mine.

Needless to say theres no length in the red wires to cut and repace the connectors. Boats!

I shall report back.
Do the terminals show any evidence of overheating? Are you confidant the heat is from the relay itself?

On second look, the solenoid appears to trigger the relay to close. Is the relay welded closed at this point, keeping the red wires continuously energized? Is the solenoid at fault? Why should it require replacement so often???

Something strange going on.
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Old 27-08-2016, 10:26   #11
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Re: Relay - heat in wire. Replacement part?

Quote:
Originally Posted by redsky49 View Post


Do the terminals show any evidence of overheating? Are you confidant the heat is from the relay itself?
The bare connectors are not. The right more than the left. There is no vusabke sign such as melting.

My initial reason to inspect them is they must be 15 years old, and if in operation constantly they must be at life expectancy.

Anyway, when the sun goes down I will disconect the leads, clean etc. Might need to be tomorrow night as I have a hot date that won't appreciate Engine Room Hands.
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Old 27-08-2016, 10:42   #12
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Re: Relay - heat in wire. Replacement part?

"...as I have a hot date..."

Glad to see a man with his priorities straight!
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Old 27-08-2016, 10:48   #13
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Re: Relay - heat in wire. Replacement part?

Quote:
The solenoid splits the battery banks for charging so the engine battery gets bulk power on the engine start, supplied by the alternator. It then supplies bulk to the house bank.
Or this is what i am lead to believe. I change the solenoid about every year.

if that relay is sharing an alt and is hot with the engine off you have a problem that needs to be figured out. before you start just buying parts. (are are you talking about the solinoid above?)

what is this relay for? what does it activate from? how much current is it passing for normal operation?

all of this should be figured out before you start throwing parts at it.
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Old 27-08-2016, 10:56   #14
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Re: Relay - heat in wire. Replacement part?

Quote:
Originally Posted by redsky49 View Post

On second look, the solenoid appears to trigger the relay to close.

my best guess is common ground. each with own trigger.
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Old 27-08-2016, 10:58   #15
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Re: Relay - heat in wire. Replacement part?

Quote:
Originally Posted by MarkJ View Post
My French built Beneteau has a 4 pin relay, photo below, with the right side red wire quite hot. I can hold my finger on it for 4 seconds before its too hot.

The engine is off. Solar panels are on generating about 10 amps.

Is this an indicator of trouble?

I have searched the net unsuccessfully for a replacement relay to no avail. There's a confusing myriad of them.

Can you identify a replacement?

Details: G Cartier
12 V 50A
4 pin

I really have no idea what its for.
If the relay itself isn't that hot. Replace the connection to the wire.
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